Energy Audit
Energy audit is the easiest way to achieve higher profitability in a manufacturing setup. Industrial energy audit carried out by B.E.E. Certified Energy Auditors can yield results for any type of manufacturing plant in terms of electrical energy saving and fuel saving. Typically a plant can save a minimum of 5% energy through our energy audit services. Energy audit should be a voluntary exercise as it saves production or manufacturing costs and has a direct impact on profitability. It is mandatory for energy-intensive industries to carry out a periodic energy audit and some States like Gujarat have also mandated Gujarat Electrical Inspector Energy Audit. Whereas the Central Government has mandated frequent energy audit for energy intensive industries such as steel, cement, aluminum etc.
Energy is one of the easiest controllable cost components in manufacturing yet it is the most neglected in many cases. Manufacturers can actually improve their profitability by optimizing their energy usage through energy conservation and energy efficiency.
Energy conservation is an ongoing process as new systems develop and equipment ageing take place. While several plants do put energy conservation measures in place an energy audit by certified experts helps in fast-tracking the progress towards energy efficient operations.
In a manufacturing setup, energy can be saved through
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Plugging leakages in the existing systems (energy saving)
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Optimization of technical processes (energy efficiency)
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Use of advanced technology retrofits (system efficiency)
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Optimization of non-technical processes (process efficiency)
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Replacement of old systems by new-age systems (system efficiency)
As per IEA (International Energy Agency) end-use energy efficiency can result in maximum mitigation of Green House Gases (GHG). It estimates that end-use fuel and electricity efficiency would be responsible for 34% of total mitigation. Whereas renewable would be responsible for 17%. So energy conservation and energy efficiency is not just beneficial in terms of cost-saving but it also helps in sustainability.
Energy savings can be in the form of direct saving of fuel being used in process or electrical power. It also leads to saving of derived energy such as steam, compressed air, hot water etc. the savings of which result in saving of manufacturing costs.
(Aluminum smelter energy audit case-study : Available on request. Drop a mail to info@EnercoEnergySolutions.com or Enerco@Ymail.com)
Energy Audit by a competent team led by B.E.E. Certified Experts can help a plant save at least 5% on Energy bills. This can have immense benefit for manufacturers who wish to cut down on their cost of production. Combined with data-driven intelligent automation can help a manufacturer save significant amount and directly impact their bottom-line. We did carry out an IIoT study for a steel manufacturer. See our Industry 4.0 IIoT case-study to understand the savings.
Our team of B.E.E. Certified Energy Auditors and Engineers can help you in saving significant energy. Book a free online session with our experts to learn how you can get started on your energy saving journey.
Highlights of our Energy Audit capabilities :
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Energy Audit team is led by IIT-B alumnus B.E.E. certified & accredited energy auditor with 35+ years of industrial energy audit experience across a variety of manufacturing industries and sectors.
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Our team consists of Harvard Certified Sustainability expert, B.E.E. Certified Energy Auditors, B.E.E. Certified Energy Managers, Senior Engineers and Junior Engineers with a rich experience and deep knowledge of industrial energy audit services.
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We cover 360° of energy consumption as part of the audit - i.e. electrical energy, equipment efficiency, utilities such as pumps, compressors, cooling towers, boilers, turbines etc. and also thermal energy through IR thermography. In some cases we also carry out process audit if permitted by the client. In the past we have identified significant energy saving opportunities through process audits as well.
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All energy saving projects and assignments are closely monitored by the company's founding team through -
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Daily progress review and reporting
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Weekly progress review and reporting
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Timely customer updates and query resolutions
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We adopt a highly systematic approach and divide the entire assignment into 3 phases i.e. Pre-visit, Visit and Post-visit to ensure maximum possible energy saving in your plant.
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Our focus is on difficult to identify and simple to implement energy saving solutions.
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All the energy saving recommendations made post the energy audit have an attractive payback ranging from a few months to 12 months. In some cases the payback period could be 18 months or higher.
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The energy saving recommendations made by us are divided into 3 types:
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Zero / low investment: Primarily operational and maintenance recommendations or small energy saving retrofits.
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Medium investment: Some mid-size retrofits or technology upgradation.
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High investment: Major technology upgradations and / or energy saving project which could be taken up strategically.
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We believe that energy saving is a journey and not a destination. Owing to our strong commitment to the cause of environment protection we have had the pleasure of saving around 5% to 8% on energy bills for our customers. Have a quick look at our energy audit case-study to understand more about our capabilities and also check out customer testimonials.
You may also like to go through our sample energy audit report of an actual energy audit of a steel plant.
(Aluminum smelter energy audit case-study : Available on request. Drop a mail to info@EnercoEnergySolutions.com or Enerco@Ymail.com)
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What is energy audit?In simple terms an energy audit is a complex technical assessment of present energy consumption of an Industrial unit (industrial energy audit) or a Commercial Facility or a Community Complex (Hospital, Offices, Shopping Malls etc.) for the purpose of reduction in wasteful consumption. The Objective Accumulating data at various energy points Identifying energy losses and critical junctions Enabling energy conservation and cost savings The Methodology Analyzing the performance of each equipment by Certified B.E.E. Energy Audit Experts using most advanced instruments and equipment Collating the parameter data with benchmarks Manifesting and implementing corrective measures What it covers All operations, processes, products and departments in the organization All forms of energy – specifically electrical + thermal Operational efficiency of equipment like diesel generator sets, turbo generator sets and utilization of power from the electricity supply authority Evaluation of different components of the electrical network like transformers, lighting, motors, capacitors and the distribution network Study of utility equipment like air compressors, fans, pumps, blowers, air-conditioning and refrigeration, evaporative cooling, cooling towers, boilers, furnaces, thermal fluid heaters What it leads to Energy balance Heat and mass balance Establishing specific energy consumption Identifying opportunities for energy efficiency What it helps achieve Compliance with Government regulations Lower energy costs Enable faster recovery of investments Achieve better performance and lower downtime Enhanced power quality and productivity Reduced emission levels Improved Age of Equipment and complete system Reducing Global Warming Areas of Energy Audit Industrial Units – Manufacturing Units – Steel, Metal, Ceramic, Cement, Chemicals, Edible Oil, Fertilizer, Paper, Textiles etc., Processing Units, Foundries, Cold Storages etc. and several other similar units definitely benefit from industrial energy audit. Commercial Facilities – Corporate Houses, Offices, Educational Institutes, Residential Complexes, Commercial Complexes, Hotels, Shopping Malls, Hospitals, Airports etc. definitely benefit from an energy audit.
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Can industrial energy audit really help in saving manufacturing or production costs?Yes, statistically energy is one of the largest and easiest controllable costs in manufacturing. Energy-intensive manufacturing industries stand to gain the most by energy conservation but any type of manufacturing or processing plant can benefit from this and expect a saving of minimum 5% on their overall energy bills. Do check our Energy Audit case-study to see how we helped our customer save on energy costs.
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What type of plants benefit from Energy Audit?Any type of manufacturing plant can benefit from Energy Audit as the duration of audit and exact savings depend on various factors. Typically energy audit is recommended for any type of manufacturing or processing setup which is looking to save energy and save on production costs. Since it's inception Enerco has worked with a variety of Clients and achieved total customer satisfaction in each of the energy saving and sustainability related assignments.
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Is energy audit helpful even when we have an internal energy cell?It is great to have an internal energy cell. However an external expert team brings in the following benefits - 1. Decades of experience focused on energy conservation and energy efficiency. 2. Fresh perspective. 3. New technology and solutions implemented in other plants. We have conducted energy audit for various plants which have an internal energy cell and have added significant value to the Company's energy saving efforts. Thanks to our highly experienced leadership team and highly qualified advisory board.
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How much energy can my plant save through energy audit?Energy saving in every plant depends on a variety of factors such as - 1. Plant process. 2. Age of plant. 3. Equipment type. 4. Time since last audit. 5. Maintenance of equipment. Etc. Etc. However based on our experience a plant could save anywhere between 5% and 10% of energy which could translate to 3% and 5% on SEC or total energy bill. Do see our energy audit case-study to understand how we helped a customer save ~10% on their energy bill.
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How frequently should a energy conservation audit be carried out?Energy audit should be carried out once every 2-3 years for a typical manufacturing unit. This ensures that the plant is always optimized and the momentum of energy conservation is maintained within the plant team members. Although some energy-intensive industries such as Steel, Cement, Thermal Power Plants carry out energy audit once every 15 to 24 months.
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What should be the qualifications of Energy Audit team?Energy Audit should be carried out by B.E.E. Certified Energy Auditor, B.E.E. Certified Energy Managers and Engineers. The team composition could vary but the audit should be led by an auditor only. All the energy audits undertaken by ENERCO is led by IIT-B alumnus Energy Auditor with a rich experience across domains and sectors. We have a team of global expertswith immense experience in sustainability.
Any specific query on Energy Audit or Energy Conservation? Get in touch and we would be glad to assist you.
Need more information on energy conservation for your manufacturing facility? Do check out our Videos on Energy Conservation and Energy Audit and the Knowledge Corner page which is frequently updated with interesting content. Energy Audit carried out by our experts can result in significant reduction in your production costs.